Optical Component Precision Shaping via Segmented Glass Molding
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Solution Overview
Problem
The existing methods for manufacturing optical components using glass molding often result in components with insufficient shape accuracy, affecting mounting precision in light emitting devices.
Innovation Solution
A method involving a base with specific projections and regions for light control and non-light control areas, where the optical component's surfaces are processed to include a light reflecting surface with precise angular boundaries, allowing for high accuracy in shape formation and reflectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If glass molding with a mold is used to manufacture optical components, then productivity is improved through batch manufacturing, but manufacturing precision deteriorates due to insufficient shape accuracy
Solution Approach 1:
The manufacturing process is segmented into two distinct stages: (1) bulk glass molding to form the base shape with approximate dimensions, and (2) precision surface processing to achieve the final accurate shape. This segmentation allows the high-productivity molding process to handle mass production while the precision processing stage corrects any shape inaccuracies, thereby resolving the contradiction between productivity and manufacturing precision.
Solution Approach 2:
The glass molding process performs preliminary shaping of the optical component base before the final precision processing. This preliminary action creates a near-finished product that requires minimal material removal in subsequent precision processing steps, thus maintaining high productivity while enabling achievement of precise shape accuracy in the final product.
2Ease of manufacture
If glass molding is used to form optical components, then ease of manufacture is improved through simple molding processes, but manufacturing precision worsens due to inadequate shape control
Solution Approach 1:
The manufacturing process is divided into a simple high-productivity molding stage for bulk production and a subsequent precision processing stage for shape accuracy. This segmentation maintains the ease of manufacture benefit from simple molding while adding a controlled processing step to achieve precise shape control, resolving the contradiction between ease of manufacture and manufacturing precision.
3Reliability
If reflective films are applied to molded glass components, then optical functionality is improved through enhanced reflectivity, but manufacturing precision worsens due to mounting accuracy issues
Solution Approach 1:
The precision surface processing is performed as a preliminary action before mounting the optical component. This ensures that the mounting surfaces and positioning features are precisely formed beforehand, eliminating shape accuracy issues that would otherwise affect mounting precision and compromising the reliability of the optical reflectivity function.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the production of optical components with improved accuracy and uniformity, enhancing the reflectivity and mounting precision in light emitting devices.
Implementation Method 1
a light reflecting surface provided on at least one of the lateral surfaces
Data Source
AI summary
An optical component includes: an upper surface; a lower surface; a first light reflecting surface extending at least partially between the upper surface and the lower surface, the first light reflecting surface comprising a flat surface; and a rounded region formed between the first light reflecting surface and the lower surface. An angular edge is located at a first light reflecting surface side of the upper surface.